How can you make your Kanban system flexible enough to adapt to changes in demand, supply, or production?

1 Use dynamic buffers

One way to make your Kanban system flexible is to use dynamic buffers, which are the amount of inventory or work in progress that you keep between different stages of production. Dynamic buffers can help you adjust to fluctuations in demand or supply, as well as to prevent bottlenecks or shortages. To use dynamic buffers, you need to monitor your production data and customer feedback, and update your buffer sizes accordingly. For example, if you notice that a certain product is selling faster than expected, you can increase the buffer for that product to avoid running out of stock.

2 Implement pull systems

Another way to make your Kanban system flexible is to implement pull systems, which are the opposite of push systems. In a pull system, you only produce what is needed by the downstream process or the customer, rather than what is forecasted or planned. This way, you can avoid overproduction, reduce inventory costs, and respond to changing customer preferences. To implement pull systems, you need to use Kanban signals that trigger production only when there is a demand for it. For example, you can use a Kanban card that moves from the customer to the production line, indicating that a product has been ordered and needs to be made.

4 Train and empower your team

A fourth way to make your Kanban system flexible is to train and empower your team, which are the people who work on your production line and interact with your customers. Training and empowering your team can help you increase their skills, motivation, and engagement. They can also help you make faster and better decisions, communicate effectively, and collaborate smoothly. To train and empower your team, you need to provide them with clear roles and responsibilities, feedback and recognition, and opportunities for learning and development. For example, you can train your team on how to use Kanban signals, how to troubleshoot issues, and how to suggest improvements.

5 Review and revise your system

A fifth way to make your Kanban system flexible is to review and revise your system, which is the overall design and implementation of your Kanban method. Reviewing and revising your system can help you ensure that your Kanban system is aligned with your production goals, customer needs, and market conditions. It can also help you avoid complacency, stagnation, and obsolescence. To review and revise your system, you need to collect and analyze data and feedback, compare your performance with your benchmarks, and make changes as needed. For example, you can review and revise your system by conducting regular audits, surveys, and meetings.

6 Experiment and learn

A sixth way to make your Kanban system flexible is to experiment and learn, which is the attitude and mindset that you adopt when using Kanban. Experimenting and learning can help you explore new possibilities, test new ideas, and learn from your failures. It can also help you embrace change, uncertainty, and diversity. To experiment and learn, you need to be curious, creative, and courageous. You also need to be open, humble, and adaptable. For example, you can experiment and learn by trying different Kanban variations, such as one-card Kanban, two-bin Kanban, or electronic Kanban.